Decorative laminates having a thick chemical resistant outer layer

Abstract

A resin impregnated and resin coated has a decorative portion coated at least 1 mil thick with a vinyl ester terminated bisphenol A epoxy resin matrix, containing hollow plastic microspheres through its thickness.

We claim: 
     
       1. A resin impregnated and resin coated, chemical resistant laminate comprising a core, and a top decorative layer containing a decorative sheet having a top exterior coating thereon, at least 1 mil thick and covering the entire decorative layer, the coating comprising a vinyl ester terminated bisphenol A epoxy resin matrix, containing hollow, transparent, microspheres made from a thermoplastic selected from the group consisting of vinylidene chloride polymers, vinylidene chloride-acrylonitrile copolymers, vinyl chloride-acrylonitrile copolymers, styrene-acrylonitrile copolymers, and vinyl chloride-vinylidene chloride copolymers having a diameter of up to about 80 microns, said laminate being heat and pressure consolidated, where said microspheres are substantially uniformly distributed through and support the epoxy resin matrix, and are effective to help support the epoxy resin coating during consolidation. 
     
     
       2. The chemical resistant laminate of claim 1, where the core layer is impregnated with a phenolic resin, and an aminotriazine-aldehyde resin is disposed between the phenolic resin in the core and the epoxy resin coating. 
     
     
       3. The chemical resistant laminate of claim 1, where the decorative sheet is a solid colored sheet. 
     
     
       4. The chemical resistant laminate of claim 1, where the microsphere containing vinyl ester terminated bisphenol A epoxy resin is applied as a composition having a viscosity of from about 850 cps to about 3500 cps at 25° C. 
     
     
       5. The chemical resistant laminate of claim 1, where the epoxy coating is from about 2 mil to 6 mil thick, and the microspheres comprise from about 1.5 volume % to about 20 volume % of the exterior coating. 
     
     
       6. A method of making a coated decorative laminate comprising the steps: (1) admixing a vinyl ester terminated bisphenol A epoxy resin with about 0.5 weight percent to about 10 weight percent, based on epoxy resin solids, of hollow, transparent, microspheres made from a thermoplastic selected from the group consisting of vinylidene chloride polymers, vinylidene chloride-acrylonitrile copolymers, vinyl chloride-acrylonitrile copolymers, styrene-acrylonitrile copolymers, and vinyl chloride-vinylidene chloride copolymers and having a diameter of from about 2 microns to about 40 microns, to provide a homogeneous composition having a viscosity of from about 850 cps. to about 3500 cps. at 25° C.,   (2) providing a decorative layer, containing a decorative sheet,   (3) coating the microsphere containing epoxy composition at least 1 mil thick over the entire top of the decorative sheet, to provide an outer epoxy resin matrix containing supporting microspheres,   (4) drying the coated decorative sheet,   (5) placing the dried, coated, decorative sheet on a resin impregnated core, and   (6) heat and pressure consolidating the decorative sheet and core, where said microspheres expand during steps (4) and (6), are substantially uniformly distributed through the epoxy resin matrix after step (6), and are effective to help support the coating of epoxy resin during consolidation.   
     
     
       7. The method of claim 6, where the decorative laminate contains a solid color decorative sheet. 
     
     
       8. The method of claim 6, where the core layer is impregnated with a phenolic resin, and aminotriazine-aldehyde resin is disposed between the phenolic resin and the epoxy resin. 
     
     
       9. The chemical resistant laminate of claim 1, where the microspheres are made from polyvinylidene chloride terpolymer. 
     
     
       10. A resin impregnated and resin coated, chemical resistant laminate comprising a core, and a top decorative layer containing a decorative sheet having a top exterior coating thereon, at least 1 mil thick and covering the entire decorative layer, the coating comprising a vinyl ester terminated bisphenol A epoxy resin matrix, containing hollow, transparent, microspheres made from a thermoplastic containing the ##STR4## and having a diameter of up to about 80 microns, said laminate being heat and pressure consolidated, where said microspheres comprise from about 1.5 volume % to about 20 volume % of the exterior coating, are substantially uniformly distributed through and support the epoxy resin matrix, and are effective to help support the epoxy resin coating during consolidation. 
     
     
       11. The chemical resistant laminate of claim 10, where the microspheres are made from polyvinylidene chloride terpolymer. 
     
     
       12. The method of claim 6, where the microspheres are made from polyvinylidene chloride terpolymer.